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HVAC and Plumbing Distributor
Picture of Steven Simmons

Steven Simmons

Technical Services Manager
Southwest District

Flame Simulator

You go on a no heat call on a gas pack/ furnace. All the burners ignite, but then go out followed by the furnace showing an ignition failure code. After cleaning or replacing the flame rod, the furnace gives the same trouble. So, what now? What is the faulty component? The sensor, sensor wire, ignition board, or grounding?

There is a tool that can be used to verify the circuitry for the flame sensor. This tool can help you troubleshoot the components involved, which can prevent replacing parts that are not bad. We call this tool a “Flame Simulator”.
Safety First:
THIS TOOL SHOULD NEVER BE LEFT IN A UNIT BEYOND THE PARAMETERS OF TESTING. DOING SO WILL DIRECTLY VOID THE UNIT’S UL SAFETY LISTING.

What does it look like?

This tool is homemade and is a fraction of the cost of a store-bought simulator. There are a couple brands out there that can be purchased, but they are hard to find. It is customizable in the sense that you can add a small amount of wire to it or even an alligator clip to the bare end.

How is it made?

It is best to solder the connections to ensure they do not come loose.

How to use it

  1. Remove the female crimp connector from the flame rod within the unit.
  2. Connect the female connector to the male spade of the simulator.
  3. Call for heat on W1 with gas on or off.
  4. When the gas valve receives 24vac, touch the other end of the simulator to ground in the unit. If you have spark ignition, it will be sparking at this time. If you have Hot Surface Ignition then there will be a short period after it glows before the board is supposed to send 24vac to the gas valve.
  5. If you touch it to ground too early, the unit will give an “abnormal flame-proving signal” meaning: flame is proved while the gas valve is de-energized.
This will tell the board that the flame exists.

Results

If the unit repeats the ignition failure when using the Flame Simulator:
First: Verify that all of the ground wires are intact in the unit, primarily on the gas valve and the ignition board.
Second: Try the same test with a new wire from the board to the simulator.
Lastly: replace the control board.

If the unit does not give an ignition failure code while using the simulator but does when connected to the flame rod:
1st- clean the flame rod again
2nd- verify the DC Microamps while in series with the flame rod (Carrier is typically 4-6)
3rd-replace if out of range or in the bottom of the range (less than 5)

The items needed to make the Flame Simulator are best bought in multiples, so you should make your HVAC buddies one as well. Always remember, this is a tool and not a part.

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Alabama Locations

Anniston (256) 241-3026 105 E D St, Anniston, AL 36201
Auburn (334) 734-8011 2295 1st Ave, Opelika, AL 36801
Birmingham (205) 250-7714 516 31st St N, Birmingham, AL 35203
Dothan (334) 836-1035 205 Wedgewood Dr, Dothan, AL 36303
Gulf Shores (251) 968-2660 820 Commerce Dr, Gulf Shores, AL 36542
Huntsville (256) 859-2691 391 Nick Fitcheard Rd NW, Huntsville, AL 35806
Loxley (251) 964-2707 30020 Co Rd 49, Loxley, AL 36551
Mobile (251) 476-2220 5522 W Commerce Blvd West, Mobile, AL 36619
Montgomery (334) 262-4855 861 Plantation Way, Montgomery, AL 36117
Muscle Shoals (256) 383-6904 107 Commerce St, Muscle Shoals, AL 35661
Tuscaloosa (205) 632-7176 5030 Old Montgomery Hwy, Tuscaloosa, AL 35405

Georgia Locations

Albany(229) 432-5254205 Baldwin Dr, Albany, GA 31707
Athens(706) 548-2563105 Whitetail Way, Bogart, GA 30622
Atlanta(404) 875-77551290 Tacoma Dr NW, Atlanta, GA 30318
Augusta(706) 651-19503618 Wrightsboro Rd, Augusta, GA 30909
Brunswick(912) 265-5193275 Rose Dr, Brunswick, GA 31520
Columbus(706) 322-38706201 W Hamilton Park Rd, Columbus, GA 31909
Conyers(770) 918-9132335 Gees Mill Business Pkwy NE, Conyers, GA 30013
Forest Park(404) 361-24745158-C Kennedy Rd, Forest Park, GA 30297
Gainesville(770) 297-93352472 Hilton Dr, Gainesville, GA 30501
Lawrenceville(678) 442-10602111 Cedars Rd SE, Lawrenceville, GA 30043
Lithia Springs(770) 948-3451320 Thornton Rd #106, Lithia Springs, GA 30122
Macon(478) 474-85445527 Thomaston Rd, Macon, GA 31220
Marietta(770) 426-05511060 Triad Ct, Marietta, GA 30062
Newnan(770) 239-210570 Enterprise Ct, Newnan, GA 30265
Peachtree Corners(770) 239-21006675 Jones Mill Ct, Peachtree Corners, GA 30092
Savannah(912) 232-1228103 Central Jct Blvd, Savannah, GA 31405
Statesboro(912) 764-8841126 W Parrish St, Statesboro, GA 30458
Valdosta(229) 245-8200363 Connell Rd, Valdosta, GA 31602
Warner Robins(478) 953-3727110 Byrd Way, Warner Robins, GA 31088

South Carolina Locations

Hardeeville (843) 867-2143 132 Red Oaks Ln, Ridgeland, SC 29936
Hilton Head (843) 689-3404 3715, 21 Hunter Rd, Hilton Head Island, SC 29926

Florida Locations

Fort Walton Beach (850) 244-2017 76 Beal Pkwy SW, Fort Walton Beach, FL 32548
Panama City (850) 913-0585 800 W 13th St, Panama City, FL 32401
Pensacola (850) 438-1005 4405 N. Palafox Street, Pensacola FL 32505

Mississippi Locations

Hattiesburg(601) 579-96701851 Lincoln Rd, Hattiesburg, MS 39402
Ocean Springs(228) 497-5090Sunplex Industrial Park, 5717 Suntec Drive, Ocean Springs, MS 39564

Commercial Sales

Norcross – North Georgia Hub
(800) 282-4911

Birmingham – North Alabama Hub
(205) 250-7714

Macon – Southwest Hub
(800) 342-9250

Loxley – Gulf Coast Hub
(800) 239-7419

Savannah – Southeast Hub
(800) 822-7617

Commercial Parts

[email protected]
(844) 99-CHILL

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